Conveyor systems and methods for sorting merchandise using interchangeable and assignable sortation modules

ABSTRACT

There is provided a conveyor assembly for sorting merchandise items. In one form, the conveyor assembly includes: a merchandise identification module; sortation modules each comprising a multi-directional sorting portion with two sets of rollers, a first wing including a third set of rollers, a second wing including a fourth set of rollers, and a controller configured to receive an IP address; a first, disassembled state of the sortation modules; a second, assembled state of the sortation modules; a merchandise database; and a control circuit configured to receive identifying information about an unsorted merchandise item, assign a unique IP address to each sortation module corresponding to the position of the sortation module, determine a sortation destination for the unsorted merchandise item, determine the sortation module corresponding to the sortation destination; and instruct the controller of the corresponding sortation module to divert the unsorted merchandise item to the sortation destination.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/797,061, filed Jan. 25, 2019, which is incorporated by reference inits entirety herein.

TECHNICAL FIELD

This invention relates generally to conveyor assemblies, and moreparticularly, to conveyor assemblies composed of interchangeable andassignable sortation modules.

BACKGROUND

In the retail setting, shipments of merchandise are constantly beingreceived at shopping facilities and merchandise distribution centers.The merchandise items that are received need to be quickly andefficiently sorted into various desired categories by a conveyorassembly. In turn, the sorted items can then be transported to anappropriate location within the shopping facility and merchandisedistribution center, such as to designated shelving.

The merchandise receiving areas of different shopping facilities andmerchandise distribution centers, however, often have different sizesand dimensions that may make it difficult to accommodate a large, fixedconveyor assembly. It would be desirable to provide a modular conveyorassembly that can be readily assembled to a desired configuration when ashipment arrives and then readily disassembled and stored following thesortation process. Further, it would be desirable to provide a conveyorassembly composed of sortation modules that can each be readilyinterchanged, replaced, and reconfigured within a conveyor assemblychain and that can each be assigned defined positions within the chain.

BRIEF DESCRIPTION OF THE DRAWINGS

Disclosed herein are embodiments of systems, apparatuses and methodsusing a conveyor assembly to sort merchandise. This description includesdrawings, wherein:

FIG. 1 is a perspective view of a conveyor assembly in accordance withsome embodiments;

FIG. 2 is an enlarged perspective view of a portion of the conveyorassembly of FIG. 1;

FIG. 3 is an enlarged perspective view of a portion of the conveyorassembly of FIG. 1;

FIG. 4 is a schematic diagram of a conveyor assembly in accordance withsome embodiments;

FIG. 5 is a schematic diagram of portions of a sortation module inaccordance with some embodiments;

FIG. 6 is a schematic diagram of rollers of a sortation module inaccordance with some embodiments;

FIGS. 7A and 7B are schematic diagrams of a conveyor assembly inaccordance with some embodiments;

FIG. 8 is a block diagram in accordance with some embodiments;

FIG. 9 is a block diagram in accordance with some embodiments;

FIG. 10 is a block diagram in accordance with some embodiments;

FIG. 11 is a flow diagram in accordance with some embodiments; and

FIG. 12 is a schematic diagram in accordance with some embodiments.

Elements in the figures are illustrated for simplicity and clarity andhave not necessarily been drawn to scale. For example, the dimensionsand/or relative positioning of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of various embodiments of the present invention. Also,common but well-understood elements that are useful or necessary in acommercially feasible embodiment are often not depicted in order tofacilitate a less obstructed view of these various embodiments of thepresent invention. Certain actions and/or steps may be described ordepicted in a particular order of occurrence while those skilled in theart will understand that such specificity with respect to sequence isnot actually required. The terms and expressions used herein have theordinary technical meaning as is accorded to such terms and expressionsby persons skilled in the technical field as set forth above exceptwhere different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

Generally speaking, pursuant to various embodiments, systems,apparatuses and methods are provided herein using a conveyor assemblyuseful for sorting merchandise items. In one form, the conveyor assemblycomprises: a merchandise identification module configured to receiveidentifying information about merchandise items to be sorted by theconveyor assembly; a plurality of sortation modules for moving andsorting the merchandise items, each sortation module comprising: amulti-directional sorting portion with a first set of rollers configuredto propel merchandise items in a first direction and a second set ofrollers configured to divert merchandise items in a second direction; afirst wing adjacent the sorting portion and comprising a third set ofrollers configured to divert merchandise items to a first sortationdestination; a second wing adjacent the sorting portion and comprising afourth set of rollers configured to divert merchandise items to a secondsortation destination; a controller operatively coupled to the secondset of rollers and configured to divert merchandise items along one ofthe first and second wings to the first and second sortationdestinations, respectively, the controller configured to receive anInternet Protocol (IP) address corresponding to the sortation module; afirst, disassembled state of the plurality of sortation modules in whichat least one of the plurality of sortation modules is not linked toanother sortation module; a second, assembled state of the plurality ofsortation modules in which the sortation modules are coupled to oneanother to define a chain of sortation modules; a merchandise databasewith a record corresponding to merchandise items to be sorted; and acontrol circuit communicatively coupled to the merchandiseidentification module, the controller of each sortation module, and themerchandise database, the control circuit configured to: receiveidentifying information about an unsorted merchandise item to be sortedby the conveyor assembly from the merchandise identification module;assign a unique IP address to each sortation module, each IP addresscorresponding to a position of each sortation module in the chain ofsortation modules when in the second, assembled state; determine asortation destination for the unsorted merchandise item to be sorted bythe conveyor assembly based on the merchandise database; determine thesortation module corresponding to the determined sortation destination;and instruct the controller of the sortation module corresponding to thedetermined sortation destination to energize the second set of rollersto divert the unsorted merchandise item to the determined sortationdestination.

In some implementations, in the conveyor assembly, at least one rollerof the first set of rollers is a motor powered roller and at least oneroller of the second set of rollers is a motor powered roller. In someimplementations, the controller of each sortation module comprises afirst roller motor control portion and a second roller motor controlportion; the first roller motor control portion configured to controlrotation of at least one of the second set of rollers in a clockwisedirection to divert merchandise items along the first wing to the firstsortation destination; and the second roller motor control portionconfigured to control rotation of at least one of the second set ofrollers in a counterclockwise direction to divert merchandise itemsalong the second wing to the second sortation destination. In someimplementations, the control circuit is configured to assign the uniqueIP addresses to the sortation modules in ascending or descendingsequential order as one proceeds downstream from the merchandiseidentification module. In some implementations, the conveyor assemblyfurther comprises: a third, assembled state in which the plurality ofsortation modules have been reconfigured to different positions in thechain of sortation modules; the control circuit assigning a new IPaddress to each sortation module depending on the sortation module's newposition in the chain of sortation modules. In some implementations, theconveyor assembly further comprises: a fourth, assembled state in whichone of the plurality of sortation modules in the chain of sortationmodules has been replaced with a new sortation module; a controller ofthe new sortation module receiving a new IP address corresponding to thenew sortation module's position in the chain of sortation modules. Insome implementations, the control circuit and the controllers of thesortation modules are configured to communicate with one another todetermine the number and relative positions of the sortation modules inthe chain with respect to one another. In some implementations, themerchandise database contains one or more predetermined characteristicsof merchandise items to be sorted; the control circuit assigns thesortation destination for the unsorted merchandise item to be sortedbased on the one or more predetermined characteristics. In someimplementations, the merchandise identification module comprises a scantunnel or arm positioned above or adjacent an input set of rollers tothe conveyor assembly; and the control circuit is disposed in the scantunnel or arm. In some implementations, the conveyor assembly furthercomprises: a non-sortation destination configured to receive an unsortedmerchandise item that could not be identified by the merchandiseidentification module or that could not be located in the merchandisedatabase.

In another form, there is provided a method for sorting merchandiseitems using a conveyor assembly, the method comprising: by a merchandiseidentification module, receiving identifying information aboutmerchandise items to be sorted by the conveyor assembly; providing aplurality of sortation modules for moving and sorting the merchandiseitems, each sortation module comprising: a multi-directional sortingportion with a first set of rollers configured to propel merchandiseitems in a first direction and a second set of rollers configured todivert merchandise items in a second direction; a first wing adjacentthe sorting portion and comprising a third set of rollers configured todivert merchandise items to a first sortation destination; a second wingadjacent the sorting portion and comprising a fourth set of rollersconfigured to divert merchandise items to a second sortationdestination; a controller operatively coupled to the second set ofrollers and configured to divert merchandise items along one of thefirst and second wings to the first and second sortation destinations,respectively, the controller configured to receive an Internet Protocol(IP) address corresponding to the sortation module; coupling theplurality of sortation modules to one another to define a chain ofsortation modules; storing records in a merchandise databasecorresponding to merchandise items to be sorted; and by a controlcircuit: receiving identifying information about an unsorted merchandiseitem to be sorted by the conveyor assembly from the merchandiseidentification module; assigning a unique IP address to each sortationmodule, each IP address corresponding to a position of each sortationmodule in the chain of sortation modules when in the second, assembledstate; determining a sortation destination for the unsorted merchandiseitem to be sorted by the conveyor assembly based on the merchandisedatabase; determining the sortation module corresponding to thedetermined sortation destination; and instructing the controller of thesortation module corresponding to the determined sortation destinationto energize the second set of rollers to divert the unsorted merchandiseitem to the determined sortation destination.

In another form, there is provided a system for receiving and sortingmerchandise items shipped to a shopping facility, the system comprising:a shopping facility containing a plurality of merchandise items; adelivery of merchandise items received at the shopping facility; adelivery location at the shopping facility configured to receive thedelivery of merchandise items; and a conveyor assembly at the deliverylocation, the conveyor assembly comprising: a merchandise identificationmodule configured to receive identifying information about merchandiseitems to be sorted by the conveyor assembly; a plurality of sortationmodules for moving and sorting the merchandise items, each sortationmodule comprising: a multi-directional sorting portion with a first setof rollers configured to propel merchandise items in a first directionand a second set of rollers configured to divert merchandise items in asecond direction; a first wing adjacent the sorting portion andcomprising a third set of rollers configured to divert merchandise itemsto a first sortation destination; a second wing adjacent the sortingportion and comprising a fourth set of rollers configured to divertmerchandise items to a second sortation destination; a controlleroperatively coupled to the second set of rollers and configured todivert merchandise items along one of the first and second wings to thefirst and second sortation destinations, respectively, the controllerconfigured to receive an Internet Protocol (IP) address corresponding tothe sortation module; a first, disassembled state of the plurality ofsortation modules in which at least one of the plurality of sortationmodules is not linked to another sortation module; a second, assembledstate of the plurality of sortation modules in which the sortationmodules are coupled to one another to define a chain of sortationmodules; a merchandise database with a record corresponding tomerchandise items to be sorted; a control circuit communicativelycoupled to the merchandise identification module, the controller of eachsortation module, and the merchandise database, the control circuitconfigured to: receive identifying information about an unsortedmerchandise item to be sorted by the conveyor assembly from themerchandise identification module; assign a unique IP address to eachsortation module, each IP address corresponding to a position of eachsortation module in the chain of sortation modules when in the second,assembled state; determine a sortation destination for the unsortedmerchandise item to be sorted by the conveyor assembly based on themerchandise database; determine the sortation module corresponding tothe determined sortation destination; and instruct the controller of thesortation module corresponding to the determined sortation destinationto energize the second set of rollers to divert the unsorted merchandiseitem to the determined sortation destination.

Referring to FIGS. 1-3, there is shown a conveyor assembly 100 forsorting merchandise items. It is generally contemplated that theconveyor assembly 100 includes a number of sortation modules 102 thatare mobile and can be readily stored when the conveyor assembly 100 isin a disassembled state. When a shipment of merchandise is received,these sortation modules 102 can then be readily assembled and arrangedin any desired order. Following assembly, the specific position of eachsortation module 102 is determined, and each sortation module isassigned a unique IP address corresponding to its position in theassembled chain.

As shown in FIG. 1, the conveyor assembly 100 includes a merchandiseidentification module 104 configured to receive identifying informationabout merchandise items to be sorted by the conveyor assembly 100. It isgenerally contemplated that each merchandise item includes some form ofidentifying information, such as a barcode or other identificationlabel. The unsorted merchandise item is preferably deposited on an inputset of rollers 106 of the conveyor assembly 100 in an orientation (suchas right side up) such that the merchandise identification module 104can scan or read each unsorted merchandise item. As can be seen, in oneparticular form, the merchandise identification module 104 may be a scantunnel (or scan arm) positioned above or adjacent the input set ofrollers 106 to the conveyor assembly 100. Further, as described below,in this particular form, a control circuit of the conveyor assembly 100may also be disposed in the scan tunnel or arm. It should be understood,however, that the illustrated merchandise identification module 104 issimply one non-limiting example and that other types of modules may beused. Further, the input rollers 106 also are simply an illustrativeexample and are not required in the conveyor assembly 100.

In addition, as shown in FIGS. 1-3, the conveyor assembly 100 includesmultiple sortation modules 102 for moving and sorting the merchandiseitems that are preferably identical and interchangeable with oneanother. Each sortation module 102 includes a multi-directional sortingportion 108 with a first set of rollers 110 configured to propelmerchandise items in a first direction and a second set of rollers 112configured to divert merchandise items in a second direction. In FIG. 1,the first direction is along the axial direction A of the conveyorassembly chain, and the second direction is in the direction B that isperpendicular to the axial direction A. In one preferred form, whenenergized, either the first or second set of rollers 110, 112 willelevate to either continue the merchandise item moving in the firstdirection or divert it to move in the second direction.

When diverted in the second direction, the merchandise item may bediverted along one of two wings. Depending on the direction of therotation of the second set of rollers 112 (clockwise orcounterclockwise), the merchandise item will be directed along one ofthe two wings. Each sortation module 102 also includes a first wing 114adjacent the sorting portion 108 and comprising a third set of rollers116 configured to divert merchandise items to a first sortationdestination 118. In other words, as the merchandise item movesdownstream from the merchandise identification module 104, it may bediverted to the left, as shown in FIG. 1. Each sortation module 102further includes a second wing 120 adjacent the sorting portion 108 andcomprising a fourth set of rollers 122 configured to divert merchandiseitems to a second sortation destination 124. In other words, as themerchandise item moves downstream from the merchandise identificationmodule 104, it may be diverted to the right, as shown in FIG. 1.Further, as can be seen in FIGS. 1-3, the wings 114, 120 are preferablycollapsible or foldable so that the sortation module 102 is compact andreadily storable when not in use.

Accordingly, in one aspect, this disclosure is directed generally to aconveyor assembly 100 that is made up of a number of separate,interchangeable modules 102. The modules 102 may be disassembled fromone another and may be reassembled to form an overall conveyor assembly100 having multiple shapes and configurations. So, initially, prior tosortation, the conveyor assembly 100 will be in a first, disassembledstate of sortation modules 102 in which at least one of the sortationmodules 102 is not linked to another sortation module 102. In one form,it is generally contemplated that all of the sortation modules 102 willbe separate and unlinked to one another when in a disassembled state (soas to facilitate storage). Subsequently, when sortation is to beundertaken, the conveyor assembly 100 will be in a second, assembledstate of sortation modules 102 in which the sortation modules 102 arecoupled to one another to define a chain of sortation modules 102.

As addressed further below, when sortation is to be undertaken, theconveyor assembly 100 dynamically identifies the downstream modules 102and then assigns an address for each module 102, and the modules 102will operate correctly in any order following disassembly andreassembly. The conveyor assembly 100 will dynamically assign the roleof each module 102 based upon the module's physical position within the“train,” or chain, and the conveyor assembly 100 will self-sense whereeach module 102 is located. The conveyor assembly 100 assigns themodules 102 their roles, such as: first module position is fordestination lanes 1 and 2; second module position is for destinationlanes 3 and 4, etc. In one form, the conveyor assembly 100 assigns afirst IP address to the closest downstream module 102 and a second,higher IP address to the second downstream module 102. In this way, theconveyor assembly 100 can determine the relative locations of themodules 102 and then assign roles based upon these locations.

Referring to FIG. 4, there is shown a schematic representation of anexemplary conveyor assembly 200 and components thereof. The conveyorassembly 200 is composed of various modules, and in one form, it mayinclude an input set of rollers 202, a merchandise identification module204, and a plurality of sortation modules 206 (FIG. 4 shows foursortation modules 206). The input set of rollers 202, and rollers on themodules 204 and 206, may collectively define the conveying surface ofthe conveyor assembly 200. In this form, products/merchandise in cases(or other containers) may be unloaded from a delivery vehicle at adelivery location 218 (such as at the loading dock of a shoppingfacility) and may be deposited on the input set of rollers 202. Theinput set of rollers 202 may be coupled to or positioned adjacent to themerchandise identification module 204. In another form, multipledelivery vehicles may be unloaded simultaneously, and the input set ofrollers 202 may serve as a way to funnel the products so that only oneproduct passes through the merchandise identification module 204 at atime. In another form, the conveyor assembly 200 may not include aninput set of rollers 202 at all, and products may instead be unloadeddirectly from a delivery vehicle at the merchandise identificationmodule 204 one at a time.

So, in one form, it is generally contemplated that the products in ashipment to the shopping facility will be unloaded from a deliveryvehicle and placed on the conveyor assembly 200. The cases may passthrough the merchandise identification module 204 and may haveidentification labels positioned and oriented on the cases so as to beread by the merchandise identification module 204. When passing throughthe module 204, the product will be identified and sorted along theconveyor assembly 200 to one of several destination lanes/areas 214,pursuant to any of various adjustable sortation criteria. In some forms,a merchandise identification module 204 is not required at all. Instead,in some forms, a hand scanner may be used to identify the product, andthe product may then be loaded on the sortation modules 206 or aconveyor portion to the first sortation module 206.

If present, the merchandise identification module 204 generally readsidentification data from an identification label disposed on a productpassing through or adjacent the module 204. The merchandiseidentification module 204 may include one or more of any of varioussorts of readers suitable for reading various types of labels, includinga bar code reader, an RFID reader, an NFC reader, a laser imager, anoptical sensor, an image processor, or a text capture device. Generally,the label and product may have to be oriented in a certainconfiguration, such as facing upwardly and extending horizontally, so asto be readable by the reader. In addition, the merchandiseidentification module 204 may include multiple readers that areconfigured to read various orientations of the labels. Alternatively,some types of readers may not be limited by the orientation of thelabel.

In one form, the merchandise identification module 204 may be in theshape of a scan tunnel or arm. The merchandise identification module 204may include a plurality of rollers for moving the products through themodule 204. Further, at least one of the rollers may be a motor poweredroller in order to propel the products through the module 204. Themerchandise identification module 204 may also include support wheels,which facilitate mobility and storage of the module 204 when theconveyor assembly 200 is not in use. As should be evident, themerchandise identification module 204 may be any of various shapes,dimensions, and types.

As the products pass through the module 204, the product identificationlabel is read and the product is identified. As used herein, the phraseproduct identification label refers broadly to any sort of productidentifier, such as, for example, graphics that are machine readable.Additional data regarding the product may also be included on the labeland may be read by the module 204, as addressed further below. Thisidentification data (and any additional data) may be used in thesortation process to determine a destination area 214 (or destinationlane 214) for the product, as addressed below.

In turn, the merchandise identification module 204 is coupled to asortation module 206. Each sortation module 206 is then coupled toanother sortation module 206 to form a sequential arrangement of modules206. The modules 204 and 206 may be coupled in any appropriate manner.The number of sortation modules 206 may be selected so as to fit withinthe size of space available to the conveyor assembly 200, and thereby,the conveyor assembly 200 is adjustable in size and orientation by theaddition or subtraction of one or more modules 206.

In one form, the sortation modules 206 are generally identical andinterchangeable. Each sortation module 206 may include a travel portion208, a multi-directional sorting portion 210, and a wing 212. The travelportion 208 may be uni-directional and include a plurality of rollers230 configured to propel the product in a first (or forward) directionalong the rollers. The travel portion 208 is optional and need not beincluded in the sortation module 206 (see, for example, sortation module102 in FIGS. 1-3). The shape of the sortation module 206 may be adjustedto accommodate space limitations. For example, the sortation module 102need not include a travel portion 208, may be T-shaped with two wings212, or may be L-shaped with one of the wings 212 folded down orremoved.

In one form, the sorting portion 210 is multi-directional and mayinclude a first set of rollers 232 configured to propel the product inthe first (or forward) direction and a second set of rollers 234 todivert the product in a second direction (or sideways) to a sortationdestination area 214. In one form, it is contemplated that a controllermay cause the second set of rollers to “pop up,” or elevate, when aproduct is to be diverted to a destination area. Further, it isgenerally contemplated that there will be two destination areas 214 foreach sorting portion 210 (one to the left and one to the right), and thesecond set of rollers 234 are rotatable in either a clockwise orcounterclockwise manner so as to divert the product to one of these twodestination areas 214. If the product is to proceed in the first (orforward) direction, it is propelled in that direction by the first setof rollers 232, and the second set of rollers 234 do not “pop up.”

In FIG. 4, the sortation module 206 is shown with the travel portion 208arranged before the sorting portion 210. However, it should beunderstood that this arrangement may be reversed so that the productreaches the sorting portion 210 and may then proceed in any one of threedirections, i.e., straight along the travel portion 208 or sidewaysalong one of the wings 212. In some instances, this arrangement may havethe advantage of provided for three destination areas 214 (rather thanjust two). Further, as addressed above, the travel portion 208 may beomitted entirely (or may be collapsible when not in use).

In summary, the sorting portion 210 can sort products in multipledirections (e.g., left or right). In some implementations, each sortingportion 210 can include a first set rollers 232 to allow products totravel in a first direction along the conveyor assembly 200, andseparate pop-up rollers 234 that are activated to direct the product inone of the multiple directions. Sensors can detect when the product isapproaching and/or on the sortation module 206, and the controller canactivate the sortation module 206 (e.g., signal to raise the pop-uprollers 234) and a direction to route. A sensor can detect when theproduct is off of the sortation module 206 to deactivate the sortingportion 210 (e.g., a photo-eye to cause the pop-up rollers to lower).When the product does not need to be diverted, the product may passstraight onto a subsequent outbound/downstream sortation module 206.

The wing 212 includes a plurality of rollers 236 and connects thesorting portion 210 to a destination area 214. It is generallycontemplated that there may be two wings 212 for each sortation module206 with each wing 212 ending in a destination area 214. Further, eachwing 212 is preferably adjustable in length to accommodate differentspace limitations for the conveyor assembly 200. It is also preferablycollapsible to facilitate storage of the sortation module 206 when notin use. For example, the wings 212 may be foldable with respect to thesorting portion 210, and/or the travel portion 208 may be foldable withrespect to the sorting portion 210. Further, the sortation module 206may include support wheels to also facilitate storage of the module 206.

In one form, the destination areas 214 may simply be the ends of thewings 212. For example, prior to sorting, pallets 238 and carts 240 maybe arranged adjacent to the ends of the wings 212, and when the sortingis completed, the products in each destination area 214 may be moved toa corresponding pallet 238 or cart 240. Alternatively, the destinationareas 214 may be the pallets 238 or carts 240 themselves and may beentirely separate from the wings 212.

In one form, the conveyor assembly 200 may also include a non-sortationdestination area 242. This non-sortation destination 242 may beconfigured to receive an unsorted merchandise item that could not beidentified by the merchandise identification module 204 or that couldnot be located in the merchandise database. So, for example, if amerchandise item cannot be identified, it may simply proceed downstreamall the way to the non-sortation destination area/lane 242 without beingdiverted into any of the intervening sortation destinations 214.

The conveyor assembly 200 may be composed of various numbers andarrangements of rollers 222 (including powered rollers and/ornon-powered rollers). Non-powered rollers may be coupled to poweredrollers in some way, such as by a belt. In one form, it is contemplatedthat each sortation module 206 includes at least one powered roller 224in both the first and second directions. For example, at least oneroller of the first set of rollers 232 is preferably a motor poweredroller and at least one roller of the second set of rollers 234 ispreferably a motor powered roller. On the other hand, it is generallycontemplated that the rollers 236 in the two wings 212 need not includemotor powered rollers. Some or all of the motor powered rollers 224 maybe operated at an adjustable rotation speed to maintain a minimumdistance between adjacent products. The conveyor assembly 200 maymaintain a minimum distance between adjacent products through the use ofa plurality of sensors 228 disposed at predetermined locations on theplurality of sortation modules 206 to detect positions of the productstraveling along the sortation modules 206. In one form, the sensors 228may be optical sensors (or any of various other sensor types) spacedequidistantly along the conveyor assembly 200 that detect products.

In one form, there is disclosed a conveyor assembly 200 having sortationmodules 206 that are readily reconfigurable to adjust to changing ordisparate space limitations. So, for example, the conveyor assembly 200may be reconfigured for use in the back room of a shopping facility withchanging space limitations. Alternatively, the conveyor assembly 200 maybe the basis for a standardized model used in different back rooms withdifferent space limitations and that may be reconfigured differently foreach shopping facility. This conveyor assembly 200 is a scaled downmodel and is configurable. In the shopping facility context, space isoften at a premium in the back rooms of stores, so the modular nature isan advantage.

The modular conveyor assembly 200 enables multiple different sortationmodules 206 to be coupled together to form a conveyor assembly 200intended to be utilized with a product sorting system that autonomouslysorts products being unloaded from delivery trucks at a shoppingfacility. The sortation modules 206 can easily be decoupled to allow forconvenient storage and to allow the conveyor assembly 200 to be movedout of the way when not in use (e.g., in the back storage area of theshopping facility). As addressed further below, when the sortationmodules 206 are coupled together, their positions can be automaticallydetermined along the conveyor assembly 200 and/or relative to one ormore other sortation modules 206 without manual inputs (e.g., if moduleA is supposed to be placed before module B, but is instead placed aftermodule B, module A and module B will reconfigure sortationdestinations). The sortation modules 206 need not be arranged in aspecific order or arrangement of modules.

One advantage of the conveyor assembly 200 is that it tracks destinationareas (or lanes) 214 even when one sortation module 206 is replaced orinterchanged with another sortation module 206. More specifically, acontrol circuit 216 is able to track the positions of the sortationmodules 206 and adjust the operation of the units accordingly to sendproducts to the correct destination area (or zone) 214. In this context,the term control circuit (and the term controller) 216 refer broadly toany microcontroller, computer, or processor-based device with processor,memory, and programmable input/output peripherals, which is generallydesigned to govern the operation of other components and devices. It isfurther understood to include common accompanying accessory devices,including memory, transceivers for communication with other componentsand devices, etc. These architectural options are well known andunderstood in the art and require no further description here. Thecontrol circuit 216 may be configured (for example, by usingcorresponding programming stored in a memory as will be well understoodby those skilled in the art) to carry out one or more of the steps,actions, and/or functions described herein.

An example of the reconfigurability of the sortation modules 206 isshown in FIGS. 7A and 7B. FIG. 7A is a schematic diagram showing thefour sortation modules 206A, B, C, D extending sequentially from left toright in a linear arrangement. In this form, there are a total of eightdestination areas (or zones) with Lanes 1 and 2 corresponding tosortation module 206A, Lanes 3 and 4 corresponding to sortation module206B, Lanes 5 and 6 corresponding to sortation module 206C, and Lanes 7and 8 corresponding to sortation module 206 D. In FIG. 7B, the sortationmodules have been rearranged so that they are in the followingsequential order from left to right: 206C, 206D, 206A, and 206B. It isgenerally contemplated that, in preparation for each unloading option,the sortation modules 206 will be removed from a storage area where theymay be arranged haphazardly. When they are set up for unloading, it iscontemplated that they will be arranged in the desired space availablefor the conveyor assembly 200 without regard to how they have beenarranged in past unloading operations. As can be seen in FIGS. 7A and7B, it is contemplated that the assigned destination areas (or lanes)214 will remain fixed or constant regardless of the new relativepositions of the sortation modules 206.

It is also contemplated that the conveyor assembly 200 is arranged forautomatic dynamic configuration based on a reduced number of modules. Inone form, if a sortation module 206 becomes impaired, it can be replacedwith a new functional sortation module 206. The sortation can thencontinue with the same number of destination areas/lanes 214.Alternative, if a replacement sortation module 206 is not available, theconveyor assembly 200 recognizes the reduced number of sortation modules206 and can continue the sortation process with a reduced number ofdestination areas/lanes 214.

It is generally contemplated that the determination of the positions ofthe sortation modules 206 may be determined when the conveyor assembly200 is energized for an unloading and sorting operation. In one form, itis contemplated that the control circuit 216 communicates with eachsortation module 206A, 206B, 206C, and 206D to track the position ofeach sortation module. Alternatively, or in addition, it is contemplatedthat each sortation module 206A, 206B, 206C, and 206D may alsocommunicate with other sortation modules to track the position of eachsortation module relative to one another. As addressed below, thesortation modules 206 include separate controllers to facilitate thedetection of their relative positions.

In one form, this disclosure describes the use of a control circuit 216.This control circuit 216 may be housed, at least in part, at or near theconveyor assembly 200 itself, such as inside the merchandiseidentification module 204. However, it is also contemplated that controlmay be handled remotely. In one example, the conveyor assembly 200 mayinclude an input/output hub that communicates wirelessly with a shoppingfacility server facility or a cloud computing system using remoteserver(s). In this example, processing would occur remotely.

The determination of the presence and/or positions of the sortationmodules 206 may be handled in various ways. One approach is to employ amaster/slave architecture with two way communication. In one example,the control circuit 216 may query each sortation module 206, i.e., thecontrol circuit 216 transmits a signal to each sortation module 206 and,in response, each sortation module 206 transmits a return signal. Inother words, the conveyor assembly 200 may utilize a query/responsemodel with the control circuit 216 making a query to each sortationmodule 206 and expecting a response from it to ascertain the position ofthe modules 206 installed in the conveyor assembly 200. Characteristicsof these signals, or simply their presence, may be used by the controlcircuit 216 to determine the relative positions of the sortation modules206, i.e., that sortation module 206B is downstream from sortationmodule 206A.

Alternatively, in another example, each sortation module 206 may beconfigured to automatically transmit a signal upon being energized. Inother words, each sortation module 206 may self-detect its installationand position and announce its presence and position to the controlcircuit 216. This approach may rely on one-way communication toestablish position. Optionally, this approach could have each sortationmodule 206 continue to transmit a signal at predetermined time intervalsuntil receiving some sort of acknowledgment signal from the controlcircuit 216. In other words, if the sortation module 206 does notreceive an acknowledge message back from the control circuit 216, themodule 206 will wait a period of time (either random or fixed duration)and make another announcement attempt.

In another form, sensors or separate controllers of the sortationmodules 206 may be “daisy chained” together so that the each sortationmodule 206 communicates with the other sortation modules 206, i.e.,sortation module 206B “knows” that it is downstream of sortation module206A. In other words, separate controllers may provide some sort ofquery/response signals or announcement signal amongst each other todetermine relative positions. This approach may also involvecommunications and signals to the control circuit 216. Under anyapproach, this determination of relative position also enables the useof spare sortation modules 206 that can replace damaged or defectivesortation modules, thereby minimizing the down time of the conveyorassembly 200.

FIG. 8 shows a block diagram showing various components of the exemplaryconveyor assembly 200. In one form, the control circuit 216 may be incommunication with several (in this example, four) sortation modules206A-D. The control circuit 216 communicates with the sortation module206A-D to track their relative positions. The control circuit 216 mayreceive input in the form of sortation criteria in which certain typesof products are to be sorted to the same destination. The controlcircuit 216 may assign destination lanes 1 through 8 to the sortationmodules 206A-D in the appropriate positions.

Referring to FIG. 9, there is shown a sortation module 300, and theinteraction of certain components of the module 300. In one form, thesortation module 300 incorporates much of the structure (such as, forexample, the roller structure, the sorting portion 108, 210 and wings114, 120, 212) described above with respect to sortation modules 102,206. It should be understood that these structures constitutenon-limiting examples and that other forms are also possible. FIG. 9generally shows the interaction of the controller 302 with certain othercomponents of the sortation module 300.

The sortation module 300 includes a controller 302 operatively coupledto the second set of rollers 112, 234 and configured to divertmerchandise items along one of the first and second wings 114, 120, 212to the first and second sortation destinations 118, 124, 214,respectively. It is contemplated that various types of conveyorcontrollers, such as, for example, controllers from Dematic andPulseRoller, may be configured for operation in sortation modules 300.In one form, the controller 302 of each sortation module 300 controlsrotation of a powered roller to direct merchandise to a sortationdestination. In this regard, the controller 302 of each sortation module300 may include a first roller motor control portion 304 and a secondroller motor control portion 306. The first roller motor control portion304 is configured to control rotation of at least one of the second setof rollers 308 in a clockwise direction to divert merchandise itemsalong the first wing 114 to the first sortation destination 118, and thesecond roller motor control portion 306 is configured to controlrotation of at least one of the second set of rollers 308 in acounterclockwise direction to divert merchandise items along the secondwing 120 to the second sortation destination 124. In addition, asaddressed further below, the controller 302 of each sortation module 300is configured to receive an IP address 310 corresponding to thesortation module 300.

It is also contemplated that the first set of rollers 312 may alsoinclude at least one powered roller to move merchandise items to thenext downstream sortation module 300. It is generally contemplated thatthe controller 302 interacts with roller motor(s) 314 to advancemerchandise items at a desired speed and minimum distance and in desireddirections. Further, as addressed above, it is generally contemplatedthat the controller 302 interacts with sensor(s) 316 to detect thepositions of merchandise items with respect to one another so as todivert them to appropriate sortation destinations.

Referring to FIG. 10, there is shown a conveyor assembly 400, and theinteraction of the control circuit 402 and sortation modules 300 in theconveyor assembly 400. As described herein, the language “controlcircuit” refers broadly to any microcontroller, computer, orprocessor-based device with processor, memory, and programmableinput/output peripherals, which is generally designed to govern theoperation of other components and devices. It is further understood toinclude common accompanying accessory devices, including memory,transceivers for communication with other components and devices, etc.These architectural options are well known and understood in the art andrequire no further description here. The control circuit 402 may beconfigured (for example, by using corresponding programming stored in amemory as will be well understood by those skilled in the art) to carryout one or more of the steps, actions, and/or functions describedherein.

As shown in FIG. 10, the control circuit 402 may be coupled to a memory404 and may be coupled to a network interface 406 and network(s) 408.The memory 404 can, for example, store non-transitorily computerinstructions that cause the control circuit 402 to operate as describedherein, when the instructions are executed, as is well known in the art.Further, the network interface 406 may enable the control circuit 402 tocommunicate with other elements (both internal and external to theconveyor assembly 400). This network interface 406 is well understood inthe art. The network interface 406 can communicatively couple thecontrol circuit 402 to whatever network or networks 408 may beappropriate for the circumstances. The control circuit 402 may bedisposed, in part, in a merchandise identification module 104, 204 (andis communicatively coupled to the module 104, 204), may be incommunication with the server of a shopping facility, and/or may be, inpart, remote from the shopping facility. It may make use of clouddatabases and/or operate in conjunction with a cloud computing platform.

The control circuit 402 is communicatively coupled to a merchandisedatabase 410. The merchandise database 410 includes recordscorresponding to merchandise items to be sorted. It is generallycontemplated that the merchandise records include characteristics of themerchandise item used to determine how to sort that merchandise. Inother words, the merchandise database 410 contains one or morepredetermined characteristics of merchandise items to be sorted, and thecontrol circuit 402 assigns the sortation destination for the unsortedmerchandise item to be sorted based on the one or more predeterminedcharacteristics. In one simple example, each merchandise record mightcontain a specific sortation destination for each individual merchandiseitem. In other examples, each merchandise record may contain any ofvarious characteristics (nature of the merchandise item (grocery,perishable, fruit, etc.), location of shelving in the store with thatmerchandise item, quantity of the merchandise item in inventory, etc.)that may be used to determine the sortation destination for that item.

The control circuit 402 is also coupled to each of the controllers 302of the sortation modules 300 in the conveyor assembly 400. Initially, itis contemplated that the sortation modules 300 will be connected to oneanother sequentially and that the controllers (302A, 302B, 302C, 302D)will also be connected to one another in sequence (such as, for example,via cables). Upon power up, it is contemplated that the control circuit402 and the sortation module controllers 302A, 302B, 302C, 302D willcommunicate with one another to determine the number of sortationmodules 300 in the chain and to determine the relative positions of thesortation modules in the chain with respect to one another. In thisexample, it is determined that there are four sortation modules; thatcontroller 302A is upstream from the other controllers; that controller302B is downstream of 302A but upstream of the remaining controllers302C, 302D; that controller 302C is downstream of 302A, 302B butupstream of 302D; and that controller 302D is downstream of all of theother controllers.

Once the sortation modules 300 are coupled to one another and sortationis ready to begin, the control circuit 402 receives identifyinginformation about an unsorted merchandise item to be sorted by theconveyor assembly 400 from the merchandise identification module 104,204. It assigns a unique IP address to each sortation module 300 witheach IP address corresponding to a position of each sortation module 300in the chain of sortation modules 300 when assembled. Initially, it iscontemplated that each sortation module 300 may include a haphazard IPaddress unrelated to its position in the chain, such as, for example,100.200.300.0X.) However, once the control circuit 402 and controllers302A, 302B, 302C, 302D are coupled to one another and following powerup, it is contemplated that the control circuit 402 assigns a unique IPaddress to each sortation module in ascending or descending sequentialorder as one proceeds downstream from the merchandise identificationmodule 104, 204. So, for example, the control circuit 402 may assign IPaddresses in sequentially ascending order as follows: 100.200.300.01corresponding to controller 302A; 100.200.300.02 corresponding tocontroller 302B; 100.200.300.03 corresponding to controller 302C; and100.200.300.04 corresponding to controller 302D.

The control circuit 402 then proceeds with sortation. It determines asortation destination 118, 124, 214 for the unsorted merchandise item tobe sorted by the conveyor assembly 400 based on the merchandise database410. It determines the sortation module 300 corresponding to thedetermined sortation destination 118, 124, 214. The control circuit 402instructs instruct the controller 302A, 302B, 302C, 302D of thesortation module 300 corresponding to the determined sortationdestination 118, 124, 214 to energize the second set of rollers 112,234, 308 to divert the unsorted merchandise item to the determinedsortation destination 118, 124, 214.

Once sortation is completed, the sortation modules 300 can be storedaway in any desired arrangement. Then, during the next sortationoperation, they can be rearranged in a different number and differentorder in the conveyor assembly chain. The conveyor assembly 400 isreconfigurable in any order. In other words, the conveyor assembly 400includes a new, assembled state in which the sortation modules 300 havebeen reconfigured to different positions in the chain of sortationmodules 300, and the control circuit 402 assigns a new IP address toeach sortation module 300 depending on the sortation module's newposition in the chain of sortation modules 300. The sortation modules300 need not be in the same order and arrangement as in the previoussortation operation.

Further, if a sortation module 300 becomes non-functional or impaired insome manner, it can be replaced with a new sortation module 300. Forexample, assume during a sortation operation involving controller 302A,302B, 302C, 302D that the second sortation module 300 corresponding tocontroller 302B stops working. The conveyor assembly 400 may be powereddown, and the second sortation module may be decoupled from the chainand replaced with a fifth sortation module having a controller 302E.Once the fifth sortation module and controller 302E are hooked up in thechain and the conveyor assembly 400 is energized, the control circuit402 and controllers 302A, 302E, 302C, 302D will communicate to determinethe relative positions of the sortation modules and IP addresses will beassigned. Accordingly, the conveyor assembly 400 further includesanother assembled state in which one of the sortation modules 300 in thechain of sortation modules 300 has been replaced with a new sortationmodule 300, and the controller 302E of the new sortation module 300receives a new IP address corresponding to the new sortation module'sposition in the chain of sortation modules 300.

Referring to FIG. 11, there is shown a process 500 for sortingmerchandise items using a conveyor assembly. It is generallycontemplated that the process 500 may use some or all of the componentsof conveyor assemblies 100, 200, 400 described above, and the abovedescription of conveyor assemblies 100, 200, 400 is incorporated herein.It should be understood generally, however, that the process 500 may beused with any of various types of conveyor assemblies sufficient tocarry out the steps of the process described as follows.

At block 502, records are stored in a merchandise database withcharacteristics for sortation. It is generally contemplated that themerchandise database may be stored locally at the conveyor assemblystructure or may be stored remotely (such as via a store server or clouddatabase). The merchandise records contain certain criteria forsortation. In a simple example, the records may contain a specificsortation destination for each merchandise item, while in otherexamples, the characteristic may be a more general characteristic thatis used to determine the sortation destination (such as the nature ofmerchandise item, location of corresponding shelving in a store,location and/or quantity in inventory, etc.)

At block 504, sortation modules are coupled to one another to define achain of sortation modules. It is generally contemplated that thesortation modules may be stored at a store or distribution center whennot in use. When a sortation operation is to be performed, the sortationmodules are coupled to one another to form a chain of a desired numberand configuration of sortation modules. It is also contemplated that oneof the sortation modules may be coupled to a merchandise identificationmodule (near the upstream end of the chain).

At block 506, the number of sortation modules in the chain isdetermined. It is generally contemplated that a control circuit isconnected to a controller for the most upstream sortation module, andthe controllers for the various sortation modules are connected to oneanother in series. Once connected, the control circuit and thecontrollers communicate with one another to determine the number andrelative positions of the sortation modules.

At block 508, a unique IP address is assigned to each sortation modulecorresponding to its position in the chain. It is generally contemplatedthat, prior to coupling and assembly, the sortation modules will eachhave some arbitrary IP address. Following assembly, they are eachassigned a new IP address in ascending or descending sequential order asone proceeds either upstream or downstream along the chain of sortationmodules.

At block 510, the sortation process at the conveyor assembly commences.It is generally contemplated that merchandise items are deposited on theconveyor assembly, such as following unloading from a delivery vehicle.Identifying information about the merchandise items to be sorted isreceived. In one form, it is generally contemplated that the merchandiseidentification module may scan or read labels on the merchandise items.

At block 512, sortation destinations are determined for the merchandiseitems being sorted. In one form, it is contemplated that the merchandisedatabase may be accessed to determine the sortation criteria and tothereby determine the appropriate sortation destination for eachmerchandise item. At block 514, in turn, the sortation modulescorresponding to those sortation destinations are determined.

At block 516, the merchandise items are then diverted to the appropriatesortation destinations. Each merchandise item moves along the conveyorassembly until it reaches the sortation module corresponding to itssortation destination. In one form, it is generally contemplated thecontroller for the sortation module energizes a motor powered roller ineither a clockwise or counterclockwise direction to divert themerchandise item along one of two wings to the sortation destination.

At block 518, IP addresses are reassigned upon reconfiguration of thesortation modules or replacement of a sortation module. For example,once a sortation operation is completed, the sortation modules may bedecoupled and stored away. Then, during the next sortation operation,they may be reassembled and reconfigured in a different order, and IPaddresses are reassigned corresponding to the positions of the sortationmodules. Alternatively, a sortation module may become non-functional sothat it cannot be used for a sortation operation. The sortation modulecan be replaced with a new sortation module that will be assigned a newIP address when it is placed in the chain and coupled to other sortationmodules.

The conveyor assemblies 100, 200, 400 and process 500 may be used in avariety of settings. In one particular form, referring to FIG. 12, it iscontemplated that they may be used as part of a system 600 for receivingand sorting merchandise items shipped to a shopping facility 602 (suchas, for example, to a retail store selling merchandise to the public).Delivery vehicles 604 arrive at the shopping facility 602 withdeliveries of merchandise items for receipt by the shopping facility602. The shopping facility 602 includes a delivery location 606 that isconfigured to receive the delivery of merchandise (such as, for example,a loading dock 608 at the shopping facility 602 for receiving thedelivery vehicles 604 and a sorting area 610 (or non-public backroomarea) in the shopping facility 602 for containing the conveyor assembly612. The sortation operation using the conveyor assembly 612 (which mayinclude some or all of the components of conveyor assemblies 100, 200,400) may occur in this non-public backroom area. Following sortation,the merchandise items may be moved, for example, to shelving units 614in the store or to an inventory storage area 616.

Those skilled in the art will recognize that a wide variety of othermodifications, alterations, and combinations can also be made withrespect to the above described embodiments without departing from thescope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

What is claimed is:
 1. A conveyor assembly for sorting merchandiseitems, the conveyor assembly comprising: a merchandise identificationmodule configured to receive identifying information about merchandiseitems to be sorted by the conveyor assembly; a plurality of sortationmodules for moving and sorting the merchandise items, each sortationmodule comprising: a multi-directional sorting portion with a first setof rollers configured to propel merchandise items in a first directionand a second set of rollers configured to divert merchandise items in asecond direction; a first wing adjacent the sorting portion andcomprising a third set of rollers configured to divert merchandise itemsto a first sortation destination; a second wing adjacent the sortingportion and comprising a fourth set of rollers configured to divertmerchandise items to a second sortation destination; a controlleroperatively coupled to the second set of rollers and configured todivert merchandise items along one of the first and second wings to thefirst and second sortation destinations, respectively, the controllerconfigured to receive an Internet Protocol (IP) address corresponding tothe sortation module; a first, disassembled state of the plurality ofsortation modules in which at least one of the plurality of sortationmodules is not linked to another sortation module; a second, assembledstate of the plurality of sortation modules in which the sortationmodules are coupled to one another to define a chain of sortationmodules; a merchandise database with a record corresponding tomerchandise items to be sorted; a control circuit communicativelycoupled to the merchandise identification module, the controller of eachsortation module, and the merchandise database, the control circuitconfigured to: receive identifying information about an unsortedmerchandise item to be sorted by the conveyor assembly from themerchandise identification module; assign a unique IP address to eachsortation module, each IP address corresponding to a position of eachsortation module in the chain of sortation modules when in the second,assembled state; determine a sortation destination for the unsortedmerchandise item to be sorted by the conveyor assembly based on themerchandise database; determine the sortation module corresponding tothe determined sortation destination; and instruct the controller of thesortation module corresponding to the determined sortation destinationto energize the second set of rollers to divert the unsorted merchandiseitem to the determined sortation destination.
 2. The conveyor assemblyof claim 1, wherein: at least one roller of the first set of rollers isa motor powered roller and at least one roller of the second set ofrollers is a motor powered roller.
 3. The conveyor assembly of claim 1,wherein: the controller of each sortation module comprises a firstroller motor control portion and a second roller motor control portion;the first roller motor control portion configured to control rotation ofat least one of the second set of rollers in a clockwise direction todivert merchandise items along the first wing to the first sortationdestination; and the second roller motor control portion configured tocontrol rotation of at least one of the second set of rollers in acounterclockwise direction to divert merchandise items along the secondwing to the second sortation destination.
 4. The conveyor assembly ofclaim 1, wherein: the control circuit is configured to assign the uniqueIP addresses to the sortation modules in ascending or descendingsequential order as one proceeds downstream from the merchandiseidentification module.
 5. The conveyor assembly of claim 1 furthercomprising: a third, assembled state in which the plurality of sortationmodules have been reconfigured to different positions in the chain ofsortation modules; the control circuit assigning a new IP address toeach sortation module depending on the sortation module's new positionin the chain of sortation modules.
 6. The conveyor assembly of claim 1further comprising: a fourth, assembled state in which one of theplurality of sortation modules in the chain of sortation modules hasbeen replaced with a new sortation module; a controller of the newsortation module receiving a new IP address corresponding to the newsortation module's position in the chain of sortation modules.
 7. Theconveyor assembly of claim 1, wherein: the control circuit and thecontrollers of the sortation modules are configured to communicate withone another to determine the number and relative positions of thesortation modules in the chain with respect to one another.
 8. Theconveyor assembly of claim 1, wherein: the merchandise database containsone or more predetermined characteristics of merchandise items to besorted; the control circuit assigns the sortation destination for theunsorted merchandise item to be sorted based on the one or morepredetermined characteristics.
 9. The conveyor assembly of claim 1,wherein: the merchandise identification module comprises a scan tunnelor arm positioned above or adjacent an input set of rollers to theconveyor assembly; and the control circuit is disposed in the scantunnel or arm.
 10. The conveyor assembly of claim 1, further comprising:a non-sortation destination configured to receive an unsortedmerchandise item that could not be identified by the merchandiseidentification module or that could not be located in the merchandisedatabase.
 11. A method for sorting merchandise items using a conveyorassembly, the method comprising: by a merchandise identification module,receiving identifying information about merchandise items to be sortedby the conveyor assembly; providing a plurality of sortation modules formoving and sorting the merchandise items, each sortation modulecomprising: a multi-directional sorting portion with a first set ofrollers configured to propel merchandise items in a first direction anda second set of rollers configured to divert merchandise items in asecond direction; a first wing adjacent the sorting portion andcomprising a third set of rollers configured to divert merchandise itemsto a first sortation destination; a second wing adjacent the sortingportion and comprising a fourth set of rollers configured to divertmerchandise items to a second sortation destination; a controlleroperatively coupled to the second set of rollers and configured todivert merchandise items along one of the first and second wings to thefirst and second sortation destinations, respectively, the controllerconfigured to receive an Internet Protocol (IP) address corresponding tothe sortation module; coupling the plurality of sortation modules to oneanother to define a chain of sortation modules; storing records in amerchandise database corresponding to merchandise items to be sorted; bya control circuit: receiving identifying information about an unsortedmerchandise item to be sorted by the conveyor assembly from themerchandise identification module; assigning a unique IP address to eachsortation module, each IP address corresponding to a position of eachsortation module in the chain of sortation modules when in the second,assembled state; determining a sortation destination for the unsortedmerchandise item to be sorted by the conveyor assembly based on themerchandise database; determining the sortation module corresponding tothe determined sortation destination; and instructing the controller ofthe sortation module corresponding to the determined sortationdestination to energize the second set of rollers to divert the unsortedmerchandise item to the determined sortation destination.
 12. The methodof claim 11, wherein the controller of each sortation module comprises afirst roller motor control portion and a second roller motor controlportion, the method further comprising: by the first roller motorcontrol portion, causing rotation of at least one of the second set ofrollers in a clockwise direction to divert merchandise items along thefirst wing to the first sortation destination; and by the second rollermotor control portion, causing rotation of at least one of the secondset of rollers in a counterclockwise direction to divert merchandiseitems along the second wing to the second sortation destination.
 13. Themethod of claim 11, further comprising: by the control circuit,assigning the unique IP addresses to the sortation modules in ascendingor descending sequential order as one proceeds downstream from themerchandise identification module.
 14. The method of claim 11 furthercomprising: reassembling the plurality of sortation modules to differentpositions in the chain of sortation modules; and by the control circuit,assigning a new IP address to each sortation module depending on thesortation module's new position in the chain of sortation modules. 15.The method of claim 11 further comprising: replacing one of theplurality of sortation modules in the chain of sortation modules with anew sortation module; and by a controller of the new sortation module,receiving a new IP address corresponding to the new sortation module'sposition in the chain of sortation modules.
 16. The method of claim 11,further comprising: by the control circuit and the controllers of thesortation modules, communicating with one another to determine thenumber and relative positions of the sortation modules in the chain withrespect to one another.
 17. The method of claim 11, wherein themerchandise database contains one or more predetermined characteristicsof merchandise items to be sorted, the method further comprising: by thecontrol circuit, assigning the sortation destination for the unsortedmerchandise item to be sorted based on the one or more predeterminedcharacteristics.
 18. The method of claim 11, further comprising:receiving an unsorted merchandise item that could not be identified bythe merchandise identification module or that could not be located inthe merchandise database at a non-sortation destination.
 19. A systemfor receiving and sorting merchandise items shipped to a shoppingfacility, the system comprising: a shopping facility containing aplurality of merchandise items; a delivery of merchandise items receivedat the shopping facility; a delivery location at the shopping facilityconfigured to receive the delivery of merchandise items; and a conveyorassembly at the delivery location, the conveyor assembly comprising: amerchandise identification module configured to receive identifyinginformation about merchandise items to be sorted by the conveyorassembly; a plurality of sortation modules for moving and sorting themerchandise items, each sortation module comprising: a multi-directionalsorting portion with a first set of rollers configured to propelmerchandise items in a first direction and a second set of rollersconfigured to divert merchandise items in a second direction; a firstwing adjacent the sorting portion and comprising a third set of rollersconfigured to divert merchandise items to a first sortation destination;a second wing adjacent the sorting portion and comprising a fourth setof rollers configured to divert merchandise items to a second sortationdestination; a controller operatively coupled to the second set ofrollers and configured to divert merchandise items along one of thefirst and second wings to the first and second sortation destinations,respectively, the controller configured to receive an Internet Protocol(IP) address corresponding to the sortation module; a first,disassembled state of the plurality of sortation modules in which atleast one of the plurality of sortation modules is not linked to anothersortation module; a second, assembled state of the plurality ofsortation modules in which the sortation modules are coupled to oneanother to define a chain of sortation modules; a merchandise databasewith a record corresponding to merchandise items to be sorted; a controlcircuit communicatively coupled to the merchandise identificationmodule, the controller of each sortation module, and the merchandisedatabase, the control circuit configured to: receive identifyinginformation about an unsorted merchandise item to be sorted by theconveyor assembly from the merchandise identification module; assign aunique IP address to each sortation module, each IP addresscorresponding to a position of each sortation module in the chain ofsortation modules when in the second, assembled state; determine asortation destination for the unsorted merchandise item to be sorted bythe conveyor assembly based on the merchandise database; determine thesortation module corresponding to the determined sortation destination;and instruct the controller of the sortation module corresponding to thedetermined sortation destination to energize the second set of rollersto divert the unsorted merchandise item to the determined sortationdestination.
 20. The system of claim 19, wherein the delivery locationcomprises a loading dock at the shopping facility configured to receivedelivery vehicles and a sorting area in the shopping facility configuredto contain the conveyor assembly.